Index G200.2 Operating and maintenance instructions

Maintenance Instructions
G200.2
OPERATING INSTRUCTIONS
Maintenance Instructions
DIE078EN - 05.06.2019
05.06.2019/Sp/Wartungsanleitung/20057431

Disclaimer
The illustrations in this documents may deviate from the delivered product. We reserve the right to make changes
due to errors or based on technical advances.
A Word on Copyright
This document is proprietary and was originally written in German. Its reproduction and distribution in whole or in
individual parts without permission of the copyright owner is prohibited and will be prosecuted under criminal or civil
law. All rights reserved, including for translation.
© Copyright by INDEX-Werke GmbH & Co. KG Hahn & Tessky

Table of contents
Preface........................................................................................................................................................................1
General notes..........................................................................................................................................................1
Safety Instructions...................................................................................................................................................1
Service Interval - Care activities.............................................................................................................................. 5
Maintenance Summary - Care activities..................................................................................................................6
A010 - Check work area door and viewing glass.....................................................................................................7
A022 - Check hydraulic system (visual inspection)................................................................................................. 9
A036 - Check pneumatic system (visual inspection)............................................................................................. 11
A075 - Checking fill levels of the fluid tanks...........................................................................................................13
A080 - Clean and lubricate clamping device......................................................................................................... 16
A090 - Check electrical lines (visual inspection)....................................................................................................18
A095 - Visual inspection of all fluid lines and electrical cables...............................................................................19
A097 - Clean cooling lubricant outlet on clamping cylinder................................................................................... 20
A110 - Clean filter screens on chip conveyor........................................................................................................ 21
A120 - Check cooling lubricant (visual inspection)................................................................................................ 23
A129 - Check the cooling unit and the coolant...................................................................................................... 25
A130 - Check work area light (visual inspection)................................................................................................... 27
A180 - Clean the work area................................................................................................................................... 28
A267 - Cleaning the chip conveyor........................................................................................................................29
A280 - Clean labyrinth ring of spindles.................................................................................................................. 31
A330 - Check and clean the INDEX tool magazine for 6 tools............................................................................... 32
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Maintenance Instructions
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Service Interval - 2.000 Operating hours...............................................................................................................35
Maintenance Summary - 2.000 Operating hours...................................................................................................36
C010 - Check maintenance logs of servicing activities..........................................................................................37
C035 - Check work area door (optionally with electr. drive) and viewing glass......................................................38
C047 - Check tool clamping sets of the milling spindles (from Berg).....................................................................43
C050 - Checking and potentially replacing the cooling lubricant adapter (HSK tool mountings)............................46
C065 - Check telescopic covers and wipers..........................................................................................................48
C070 - Check outer wipers of linear guides...........................................................................................................49
C080 - Check all electrical connections and drive belts of the drive motors.......................................................... 50
C140 - Check cooling unit for cooling lubricant..................................................................................................... 52
C155 - Check coolant............................................................................................................................................53
C190 - Clean labyrinth rings of spindles................................................................................................................ 55
C510 - Check backup data carrier.........................................................................................................................56
C525 - Check control cabinet................................................................................................................................ 57
C540 - Check cable and hose clamps for tight seating..........................................................................................58
C555 - Replace hydraulic fluid filters..................................................................................................................... 59
C580 - Check and clean the INDEX tool magazine for 6 tools...............................................................................62
Service Interval - 4.000 Operating hours...............................................................................................................65
Maintenance Summary - 4.000 Operating hours...................................................................................................66
D010 - Cleaning of the machine............................................................................................................................ 67
D017 - Clean spring steel wiper in the area of the work area door.........................................................................69
D050 - Check the lubrication system.....................................................................................................................71
D067 - Check pneumatic system (visual inspection)............................................................................................. 73
D077 - Check tool clamping sets of the milling spindles (from Berg)..................................................................... 75
D107 - Check and clean the INDEX tool magazine for 6 tools...............................................................................78
D170 - Check the system for reconditioning the cooling lubricant......................................................................... 80
D345 - Replace belts and check belt tension........................................................................................................ 81
D455 - Replacing hydraulic fluid............................................................................................................................84
Service Interval - 8.000 Operating hours...............................................................................................................89
Maintenance Summary - 8.000 Operating hours...................................................................................................90
E030 - Check and clean the INDEX tool magazine for 6 tools............................................................................... 91
Service Interval - 5 Years........................................................................................................................................ 93
Maintenance Summary - 5 Years.......................................................................................................................... 94
I020 - Replace the pressure accumulator..............................................................................................................95
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II Maintenance Instructions
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Service Interval - 8 Years........................................................................................................................................ 97
Maintenance Summary - 8 Years.......................................................................................................................... 98
J150 - Replacing the viewing glass....................................................................................................................... 99
Table of contents
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Maintenance Instructions
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Table of contents
IV Maintenance Instructions
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Preface
General notes
The maintenance activities described in this document essentially pertain only to the
machine. Maintenance activities of auxiliary units (e.g., bar loading magazines,
exhaust systems) are described in the documentation of the specific manufacturer.
The maintenance and servicing activities must absolutely be observed. Failure to
conduct maintenance and servicing in accordance with these instructions
(especially not at the respective intervals) rules out any claims for damages. This
does not apply if it is proved that the non-compliance with the maintenance and
servicing activities is unrelated to the defect. Normal wear and tear, especially of
components such as bearings and seals, is not a defect. These components are
therefore excluded from the warranty. It is recommended to keep a written log of all
maintenance activities carried out.
The maintenance intervals are given based on the operating hours
counter / "Hydraulic system On" operating condition.
Do not clean the machine with compressed air.
Raised dirt particles may cause breathing difficulties or injuries
(especially of the sensory organs).
Furthermore, raised dirt particles or chips may reach spots where
they cause technical problems.
Do not use cotton waste for cleaning.
When cleaning with cotton waste, fibers or thread can get loose
causing safety problems.
Do not use highly volatile solvents such as benzene,
trichloroethylene or similar cleaning agents.
These cleaners may damage the seals, which can lead to safety
problems.
Do not clean the machine with a pressure washer.
Cleaning with a pressure washer results in strong corrosion.
Furthermore, bearings may be degreased and seals may become
leaking, which can lead to safety problems.
A suitable cleaning tool must be used to clean the hole in the
tool mounting.
Preface
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Maintenance Instructions
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Always specify the machine type and machine number when
ordering spare parts. This and other information about the machine
are located on the nameplate under the main switch of the control
cabinet.
When carrying out maintenance work on fluid systems (hydraulic,
lubrication, and pneumatic systems), make sure before starting the
work that the respective system has been depressurized
(accumulator drain valve / manual slide valve / emergency stop).
Safety Instructions
Maintenance is to be performed only by authorized and trained personnel. This
applies particularly to work on motors (spindle motors) or other electrical
assemblies. The instructions in the respective manufacturer documentation must be
followed for such work.
We recommend the use of original spare parts and accessories. For damages
caused by the use of parts from third-party providers, liability and warranty are
excluded. The use of such products may change the structural characteristics of the
machine and negatively affect the active or passive safety.
In general, maintenance is to be carried out with the machine turned off. The main
switch must be locked out. Even when the main switch is switched off, parts of the
machine (e.g., the control cabinet light) may still carry electricity. These parts are
labeled. In a few cases, maintenance work needs to be performed with the machine
turned on (e.g., replacement of backup batteries). These maintenance activities
must be carried out with special care.
Prior to working on the machine, it must be allowed to cool down, as hot parts may
be located under the covers.
All maintenance work on the machine must be carried out with utmost care.
Fasteners must be loosened carefully and parts must be secured against falling
down. When elastic items (springs) are removed/replaced, appropriate devices
must be used. Any (non-horizontal) axes that pose a risk of falling down must be
moved to their end positions or secured against falling down. Pedal switches must
be put aside to avoid inadvertent actuation.
For removing machine parts, suitable lifting gears must be used. Removed machine
parts must be placed in a safe position and secured against falling over.
When the control cabinet is open or the machine covers are open or removed, no
cellular or wireless phones may be used within a 2 m radius.
Flexible hydraulic hoses made of elastomer-based plastics are subject to a natural
aging process and should be replaced regularly. The machine operator is
responsible for compliance with the laws and regulations of the country of use with
regard to the use of hydraulic hoses. In Germany, the relevant institutions
recommend a renewal cycle of 6 years for the hydraulic hoses.
Damaged power supply and fluid lines must be replaced immediately.
It may be necessary to remove or disable protective equipment to carry out repairs.
Any removed protective equipment must be reinstalled immediately after finishing
the repair.
Preface
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Suitable climbing aids (ladders or steps) may be required to
perform maintenance or service work.
The currently valid safety regulations, as well as the specific
manufacturer’s information for the intended use must be
observed.
After all maintenance work and work on electrical assemblies, a test run or
functional test must be performed.
Additionally, the general safety precautions in the operating manual
“Safety instructions for CNC turning machines” must be
observed. The safety precautions, as a separate document, are part
of the INDEX-TRAUB user documentation.
When carrying out maintenance work on fluid systems, (hydraulic,
lubrication, and pneumatic systems), make sure before starting the
work that the respective system has been depressurized.
(accumulator drain valve/manual slide valve/emergency stop)
Preface
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Preface
4Maintenance Instructions
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Service Interval - Care activities
Service Interval - Care activities
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Maintenance Summary - Care activities
It is recommended to document the maintenance activities carried out by using the appropriate
maintenance log. The maintenance log has the document number DIE079EN - 05.06.2019.
The maintenance interval is highly dependent on the production and environmental conditions of the
machine. The determination of the appropriate interval must be made by the operator.
The maintenance interval should be between once per shift and once a week!
A010 - Check work area door and viewing glass
A022 - Check hydraulic system (visual inspection)
A036 - Check pneumatic system (visual inspection)
A075 - Checking fill levels of the fluid tanks
A080 - Clean and lubricate clamping device
A090 - Check electrical lines (visual inspection)
A095 - Visual inspection of all fluid lines and electrical cables
A097 - Clean cooling lubricant outlet on clamping cylinder
A110 - Clean filter screens on chip conveyor
A120 - Check cooling lubricant (visual inspection)
A129 - Check the cooling unit and the coolant
A130 - Check work area light (visual inspection)
A180 - Clean the work area
A267 - Cleaning the chip conveyor
A280 - Clean labyrinth ring of spindles
A330 - Check and clean the INDEX tool magazine for 6 tools
Maintenance Summary - Care activities
6Maintenance Instructions
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A010 - Check work area door and viewing glass
Orientation
Inspection and maintenance of the work area door includes several steps:
- Inspection of the viewing glass for damage.
- Checking the safety label on the viewing glass (replacement interval 8 years).
- Checking/adjusting or replacing, if necessary, the wipers.
- Checking the work area door for smooth opening/closing.
- Automatic work area door (optional). Hydraulic valves and motor, control panel,
rack and spur gear. (for hydraulic door drive)
- Automatic work area door (optional - electric door drive - follow the
manufacturer’s documentation ).
The viewing glass consists of three panes. the inner pane of tempered glass, the
central pane of polycarbonate, and the outer pane also made of polycarbonate. The
inner pane is relatively resistant. It can be cleaned with any commercially available
cleaning agents. Only the center pane is essential for the impact resistance of the
viewing glass.
The polycarbonate panes are subject to natural aging and therefore must be
subjected to regular visual inspection. Through contact with cooling lubricant, the
aging process is accelerated even further
If the viewing glass is damaged, it must be replaced. This is
necessary regardless of the extent of damage. Even with minimal
damage, the impact resistance of the glass can no longer be
guaranteed.
Heavily soiled or damaged wipers may cause damage to the inner pane. Moreover,
it may be possible that the work area door can be moved only with considerable
effort due to heavy soling or chip deposits in the wipers.
Check the guide rails of the work area door. The guide bars must be checked and
cleaned regularly so that the work area door can be moved without much effort.
Procedure
1. Check viewing glass for damage.
2. Clean the outer pane with a soft cloth or sponge and glass
cleaner or soap and water. Do not use abrasive or alkaline
cleaners (e.g., benzene, acetone or carbon tetrachloride) and
no sharp tools or sharp objects (such as razor blades or
screwdrivers).
Clean outer pane.
3. Clean inner pane.
4. Check wipers. Remove and clean the wipers. If the wipers are severely
deformed or damaged, they must be replaced. To be able to clean the door
panels evenly, be sure to reinstall the wipers after their removal aligned in
parallel and ensure that they snugly contact the work area door.
Maintenance Summary - Care activities
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5. Check the work area door for ease of movement. To do so, open and close the
work area door. If the work area door can be moved only with effort, determine
the cause. Possible causes include – depending on the work area door –
defective or improperly adjusted wipers. Chips on the guide bar or between the
door and wiper, or in the guide rollers of the work area door.
Maintenance Summary - Care activities
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A022 - Check hydraulic system (visual inspection)
Orientation
To ensure trouble-free operation, periodic checks of the oil level are necessary. The
fill level must be between the upper and lower marks on the oil sight glass.
Only use hydraulic fluid grade 15/13/10 in accordance with ISO 4406.
Viscosity other than 32 according to DIN ISO 3448 is not admissible.
For all work in connection with operating materials, the information in
the data sheets of the respective manufacturers and the information
in the document Notes on Operating Materials must be observed.
Example: Hydraulic unit G200.2
aFiller neck
bFill level indicator
cAccumulator drain valve
dMonitoring (level and temperature)
eOil drain plug
fMonitoring (system pressure)
XHydraulic fluid filter hydraulic fluid HLPD32 (VG32)
YFilter bowl
Screws on the hydraulic system, the connected components, and the
supply lines must be tightened to the manufacturer's specified
torques.
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Procedure
1. The hydraulic fluid level should always be near the top mark
when the machine is switched off. During production, the oil
level may drop after several consumers have been connected.
Check oil level at the oil sight glass.
2. Visual inspection of the hydraulic fluid. The hydraulic fluid may not exhibit any
foaming or cloudiness at the oil sight glass. In case of problems of this kind,
immediately determine the cause and correct the error. If in doubt, take a
sample for analysis and contact the manufacturer of the hydraulic fluid.
3. Check pressure setting on pressure gauge and adjust if necessary. The
operating pressure is different depending on the machine type. See the fluid
charts for the correct pressure setting.
4. Check supply and fluid lines (damage and leakage). Supply and fluid lines must
be checked for damage. Pre-damage such as kinks or abrasions should be
logged and replacement should be initiated.
Maintenance Summary - Care activities
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A036 - Check pneumatic system (visual inspection)
Orientation
To ensure trouble-free operation, periodic checks (visual inspection) of the
pneumatic system are necessary.
- Check oil level at oiler (optional).
- Check system pressure and sealing air settings.
- Check supply and fluid lines.
- Check silencers.
- Drain condensate (not applicable to auto-drain).
- Check pressure setting on the pressure differential monitoring pressure gauge.
Example: Pneumatic maintenance unit G200.2 by Festo
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
The following components are used on the system maintenance unit (X) and the
extension for sealing air on the glass scales (Y):
1. Switch-on valve (manual)
2. Pressure regulating valve for system pressure 6–8 bar
3. Pressure gauge for system pressure
4. Filter insert with retained particle size 40 µm with automatic condensate drain
5. Filter insert with retained particle size 5 µm with automatic condensate drain
6. System pressure monitoring
Maintenance Summary - Care activities
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7. Electrically actuated switch-on valve
8. Pressure sensor for pressure differential monitoring
9. Microfilter insert with retained particle size 1 µm with automatic condensate
drain
10. Filter insert with retained particle size 0.01 µm with automatic condensate drain
11. Activated carbon filter no automatic condensate drain
12. Pressure regulating valve with pressure sensor for glass scales sealing air
0.6-1.0 bar
Procedure
1. Check oil level at oiler (optional).
2. Check pressure setting on pressure gauge and adjust if necessary. An
operating pressure of 6 bar has been set at the factory.
3. Check supply and fluid lines (damage and leakage). Supply and fluid lines must
be checked for damage. Pre-damage such as kinks or abrasions should be
logged and replacement should be initiated.
4.
Example: Various silencer versions from FESTO
Check silencers.
5. Drain condensate (not applicable to auto-drain).
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A075 - Checking fill levels of the fluid tanks
Orientation
To ensure the operational safety of the machine, the fill levels of all fluid tanks must
be regularly checked, and topped off if necessary.
Operating fluids such as hydraulic fluids, cooling lubricants, lubricating greases/oils
are also subject to degradation or aging like the components involved in this
process, and must therefore be serviced, refilled or changed at regular intervals. Do
not use cotton waste and highly volatile solvents such as benzene, trichloroethylene
or similar cleaning agents. The machine must not be cleaned with compressed air.
To ensure trouble-free operation, periodic checks of the oil level are necessary.
The hydraulic fluid and lubricating oil levels should always be near the top mark
when the machine is switched off. During production, the oil level may drop after
several consumers have been connected.
The interval for this maintenance activity is strongly dependent on the operating
profile of the machine. If the machine is used in three-shift operation, this
maintenance activity must be carried out much more frequently.
Requirement
For all work in connection with operating materials, the information in
the data sheets of the respective manufacturers and the information
in the document Notes on Operating Materials must be observed.
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
Procedure
1.
Example: Lubricating oil tank
1Pressure gauge (pressure lubrication)
2Filter insert and min./max. indicators
Check fill level at lubricating oil tank.
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2.
Example: Hydraulic unit C100, C200
aFiller neck
bBase plate of hydraulic unit
cLevel control
dDrain plug
eAccumulator drain valve
Check fill level at hydraulic fluid tank.
3. Check fill level at cooling lubricant tank.
Maintenance Summary - Care activities
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